Air blown tufted fabric



Mafch 22, 1966 J, SHORT 3,241,509

AIR BLOWN 'IUFTED FABRIC Filed April 50. 1963 FIGI H04 FIGZ FIGS INVENTOR.

JOE T. SHORT MJM A TTORNEKS' March 22, 1966 J. T. SHORT AIR BLOWN TUFTED FABRIC Filed April 30, 1963 5 Sheets-Sheet 2 FIG? JOE T. SHORT March 22, 1966 J. *5. SHORT AIR BLOWN TUFIED FABRIC 5 Sheets-Sheet 5 Filed April 50, 1965 JOE T. SHORT M, n M r; M-J'M' Marh 22, 1966 J. 'r. SHORT 3,241,509

AIR BLOWN 'IUFTED FABRIC Filed April 50, 1965 5 Sheets-Sheet 4 FIG. IO FIGIZ PRIOR ART 27 FIG."

PRIOR ART FIGIG INVENTOR JOE T. SHORT BY M @014, M 1 We. JWuc/L ATTORNEY March 22 1966 .J. T. SHORT AIR BLOWN TUFTED FABRIC 5 SheetsSheet 5 Filed April 50, 1963 LONGITUDINAL DIRECTION JOE T, SHORT adzuq Ma. 49 Ms United States Patent 3,241,509 AIR BLOWN TUFTED FABRIC Joe T. Short, West Point, Ga, assignor, by mesne assignments, to Callaway Mills Company, La Grange, Ga., a corporation of Georgia Filed Apr. 30, 1963, Ser. No. 276,811 4 Claims. (Cl. 112--410) This invention pertains to improved fabrics, and in particular, to improved tufted pile fabrics. While the fabric improvement afforded by the invention is of general utility in the textile art, it finds particularly advantageous application in the floor covering art.

Tufted pile fabrics have relatively recently assumed a position of prominence in the textile art. Frequently, however, tufted pile fabrics heretofore produced have been characterized by certain deficiencies which have detracted from their advantageous properties. For example, difficulty has been encountered in producing tufted pile fabrics having a high degree of uniformity in height of pile loops which are desired to terminate at the same general elevation. This lack of loop height uniformity has been of such a magnitude as to make readily visible to the naked eye many fabric areas where loops deviate in height from their desired elevation.

Problems have also been encountered in connection with the pattern definition in fabrics wherein patterns are formed by tufted pile loops which terminate at different elevations. Such a lack of definition has frequently been compounded by difficulties in obtaining a degree of pattern definition in the direction of tufting which is the same or substantially the same as the degree of definition transversely of the direction of tufting.

In many tufted pile fabrics heretofore produced, the orientation of individual loops has been such that there frequently has been produced an undesired, visible alignment of tufted pile loops in the direction of tufting.

Additional undesirable structural characterics of tufted pile fabrics have resulted from excessive or nonuniform tension forces imposed upon strands while forming them into pile loops. Such excessive and/or non-uniform tension has resulted in less than optmium coverage of fabric backings by tufted pile loops. In addition, the crush resistance of fabrics has been impaired and individual components of strands, such as filaments or fibers, have been weakened or partially withdrawn from the strands so as to detract from the appearance of the fabric and impair the structural characteristics of the fabric. Such impairment has involved the crush resistance of the fabric and has frequently resulted in a tendency for loosened fibers to gather into unsightly rolls or pills as the fabrics are subjected to abrasion associated with normal wear.

In recognition of the need for an improved tufted pile fabric structure, it is an object of the present invention to provide such improvements which substantially obviate some or all of the fabric deficiencies heretofore noted.

It is a particular object of the invention to provide a tufted pile fabric which is charactertized by an extraordinary degree of uniformity in the height of pile loops which are intended to terminate at a common elevation.

It is likewise an object of the invention to provide an improved tufted pile, pattern fabric wherein the patterned areas formed by tufted pile loops of different heights are particularly well defined and are defined in the direction of tufting to a degree consistent with the degree of pattern definition transversely of the tufting.

It is also a principal object of the invention to provide improved tufted pile fabrics which are characterized by tufted loops formed by strands which are drawn through 3,241,509 Patented Mar. 22, 1966 a fabric backing and formed to their final configuration with significantly less tension force than has heretofore been found necessary.

It is likewise an object of the invention to provide improved tufted pile fabrics which are characterized by tufted pile loops of different heights which, regardless of height, are subjected to substantially the same tension forces while being drawn through a fabric backing and formed to their final configuration.

It is a further object of the invention to provide improved tufted pile fabrics which include a substantial number or majority of loops which are oriented such that the axes of portions of the loop legs adjacent to a fabric backing are substantially coplanar in any row of loops in the direction of tufting.

An additional object of this invention is to provide such improved tufted pile fabrics wherein the visible alignment of tufted pile loops in the direction of tufting is substantially minimized.

Still further objects of the invention are to provide improved tufted pile fabrics which are characterized by improved structural strength and a reduction in the weakening or withdrawal of strand components from the strand body.

Other objects of the invention are to provide improved tufted pile fabrics having improved crush resistance, improved backing coverage properties, and which demonstrate an improved resistance to tendencies for strand components to accumulate in unsightly rolls or pills as a result of normal fabric abrasion.

In accomplishing the objects of this invention, tufted pile fabrics are produced wherein tufted pile loops are formed by strands which are drawn through a fabric backing and formed to their final configuration with a maximum tension force applied to each strand which is substantially less than the forces heretofore found necessary. Such tufted loops are substantially free of deformation induced by stress applied longitudinally to the strands while they pass through the backing and are formed to their final loop configuration.

Patterned fabrics may be produced according to the invention wherein pattern areas are defined by tufted pile loops having relatively different heights. Such a fabric would include at least some traverse loop rows having at least one plurality of loops aligned at a first nominal height and another plurality of loops aligned at a second nominal height. The fabric would additionally include at least some longitudinal loop rows defined by continuous strands which would have at least one plurality of loops aligned at said first nominal height and another plurality of loops aligned at said second nominal height. This fabric is characterized by an average difference in height between adjacent first and second nominal height loops in longitudinal loop rows which, in relation to the average difference in height between adjacent first and second nominal height loops in transverse loop rows, is such that said height differences in both longitudinal and transverse loop rows, in general, appear visually to be substantially identical. It will be understood, however, that there will be at least some adjacent first and second nominal height loops in the aforesaid longitudinal rows which will have differences in height which deviate from the said average height difference in longitudinal loop rows.

In the patterned fabric heretofore described, the loops generally aligned at the first nominal height and the loops generally aligned at the second nominal height were formed by strand portions which were drawn through the backing and formed to their final configuration with substantially the same max-imum tension force applied thereto.

Tufted pile fabrics, according to the present invention, may be charactertized by a unique orientation of the leg portions of loops which extend through fabric backings. In this orientation, adjacent leg portions of adjacent loops in loop rows in the direction of tufting are connected on the side of the backing opposite to that where the loops projectby incremental strand portions. The fabrics of this invention often may be characterized by a majority of the aforesaid leg portions and incremental portions in each loop row in the direction of tufting being aligned such that their central axes are substantially coplanar.

In describing the invention reference will be made to preferred fabric embodiments described in connection with the accompanying drawings, in which;

FIGURE 1 is a schematic plan view of a portion of a tufted pile fabric having a parquet type pattern produced by tufted pile loops having two different elevations, which fabric is demonstrative of the state of tufted fabrics prior to the present invention;

FIGURE 2 is an enlarged, fragmentary schematic and sectional view along the section line 2-2 of FIGURE 3, viewing the fabric so as to see a loop row running transverse to the direction of tufting;

FIGURE 3 is an enlarged, fragmentary, schematic and sectional view of the FIGURE I fabric as viewed along the section line 3-3, with the line 3 3 running parallel to the direction of tufting, i.e. the direction of alignment of the continuous strands which provide the tufted loops of the fabric; p i

FIGURE 4 is a schematic plan view of a portion of a tufted pile fabric havinga parquet pattern corresponding to that shown in FIGURE 1, but demonstrating in relation to the FIGURE 1 fabric, certain of the improved fabric properties afforded by the present invention;

FIGURE 5 is anenlarged, fragmentary, schematic and sectional view of the FIGURE 4 fabric as viewed along the section line 5+5, which is directed transverse to the direction of tufting of the FIGURE 4 fabric;

FIGURE 6 is an enlarged, fragmentary, schematic, and sectional view of the FIGURE 4 fabric as viewed along the section line 66, which section line is aligned parallel to the direction of tufting of the FIGURE 4 fabric;

FIGURE 7 is a plan view photograph o fan act ual, finished fabric corresponding to the schematically illustrated fabric shown in FIGURE 4; i 7

FIGURE 8 is an enlarged, sectional view of the FIG- URE 7 fabric viewing the ends of longitudinal rows of tufted pile loops formed by continuous strands. This view corresponds to the schematic illustration set forth in FIGURE 5;

FIGURE 9, is an, enlarged, fragmentary, sectional view of the FIGURE 7 fabric illustrating a side view of a loop row defined by continuous strands. Thisview corresponds to the FIGURE 6 view of the FIGURE 4 fabric;

FIGURE 10 is an enlarged, fragmentary, and schematic side view of a loop row formed by a continuous strand of a tufted fabric as known prior to the present invention;

FIGURE ll is a sectional view of the FIGURE 10 loop row as viewed along the section line 11-41;

FIGURE 12 is an enlarged, fragmentary, and schematic side view of a loop row formed by a continuous strand which illustrates a type of loop portion orientation which maybe achieved with the present invention;

FIGURE 13 is a sectional view of the FIGURE 12 loop row as viewed along the section line 13-ll3;

FIGURE 14 is a plan view photograph of a patterned tufted pile fabric made according to the present invention and illustrating consequences of the loop orientation structure illustrated in FIGURES l2 and 13;

FIGURE 15 is a schematic, plan view of a portion of a unique tufted pile fabric which may be produced in accordance with the present invention;

FIGURE 16 is an enlarged, fragmentary sectional view taken along the section line 16-16 of the FIGURE 15 41- fabric so as to view the side of a loop row formed by a continuous strand and illustrate a unique, shallow pattern definition which may be achieved with the present invention; and

FIGURE 17 is an enlarged, fragmentary, sectional view of the FIGURE 15 fabric as viewed along the section line 17ll7 so as to view side of a loop row formed by a continuous strand and illustrate a unique, narrow pattern definition which may be achieved with the ptesent invention.

Tufted pile fabrics include as structural components a backing and continuous strands having portions which pass through the backing to form loops projecting from at least one side. In tufted fabrics having loops projecting from only one side, the adjacent legs of adjacent loops in any strand are interconnected by incremental strand portions, i.e. back stitches, lying on the face of the backing opposite to that from which the loops project.

In a tufted pile fabric, the pile height may be considered to be the distance between a pile loop, free extremity and the face of the backing from which the loop projects, with this distance being measured generally normal to this backing face. The portions of pile loops which pass through the fabric backing and extend to the extremity of the loop may be termed loop legs.

In describing tufted pile fabrics, the term pile stitch length is often employed. This length, in relation to any particular loop, usually indicates the length of strand between the center of incremental strand portions which lie on the back face of a backing on the opposite sides of the pile loop in question which projects from the front face of the backing.

A principal characterizing feature of tufted pile fabrics of the present invention resides in the consistent accuracy of loop formation. While there will inevitably be some degree of loop height randomness in a fabric made according to this invention, the degree of loop height uniformity actually achieved is outstanding in relation to that ob tained in prior art fabrics. For example, in any given fabric area having loops of the same nominal or desired height, the average height of any selected group of several adjacent loops will correspond quite closely to the average height of the other groups of adjacent loops. Thus, the loops within any portion of an area, as described, will have an average height which deviates from the average height of loops for the over-all area to a substantially lesser degree than has heretofore been obtained.

Tufted fabrics may be produced which have a pattern defined by tufted loops having relatively different heights. While such patterns are usually defined by loops which terminate at two different elevations, it is entirely possible to produce patterns with three or more differences in l'oop height or elevation.

A representative tufted pile fabric 1 of the type heretofore known is schematically illustrated in FIGURE 1. As there shown, this fabric It is patterned in a generally parquetlike configuration. The pattern of this fabric 1 is defined by loops of two different heights running in both longitudinal and transverse fabric directions.

The differences in loop height in a transverse fabric direction are illustrated in the cross-sectional view of FIGURE 2. This view illustrates the generally transversely aligned, looped ends of a plurality of continuous strands. Such aligned loops define a transverse loop row 2 which extends generally normal to the direction of tufting and includes a plurality of loops of adjacent longitudinal loop rows which are aligned in generally side by side relationship. While the loops in transverse loop rows 2 may be nearly perfectly aligned, it is possible for some slight misalignment to be deliberately effected in transverse loop rows. Such misalignment may be de sired to obviate the visual impression of distinct transverse loop rows. In any event, for the purposes of this invention transverse loop rows will be considered as the rows of adjacent, generally aligned loops existing along any cross-section extending traverse, i.e. normal to the direction of tufting.

As shown in the transverse loop row 2 illustrated in FIGURE 2, the aligned loops of adjacent, longitudinal loop rows terminate at two different nominal or desired elevations. Loops 3 terminate at a relatively low elevation and define the lower patterned portions of the fabric 1. Loops 4 terminate at a second nominal or relatively high elevation and define the upper pattern portions of the fabric 1. As will be observed, the transverse loop row 2 includes a plurality of loops 3 aligned at one nominal height and a plurality of loops 4 aligned at a second nominal height.

A longitudinal loop row 5, i.e. a loop row running in the direction of tufting and thus formed by a continuous strand, is illustrated in FIGURE 3. Longitudinal loop row 5 includes a plurality of loops 6 formed at a lower elevation corresponding to the elevation of loops 3 in transverse loop rows 2 and a second plurality of loops 7 which terminate at a high elevation corresponding to the elevation of the loops 4 of the transverse loop rows 2.

As will be observed by reference to FIGURE 2, the differences in height of adjacent high loops 4 and low loops 3 in the transverse loop row 2 is well defined and substantially constant in each instance. However, in the longitudinal loop row 5, the difference in height between adjacent nominally high and low loops such as the desirably high loop 7a and the desirably low loop 6a is not consistent along the row and the pattern definition such as in the areas of loops 6a and 7a is relatively poor.

As a result of the lack of consistency of loop height at each of the nominal loop elevations in longitudinal loop rows as reflected in FIGURE 3, the pattern definition of the FIGURE 1 fabric is impaired and the pattern definition in the longitudinal loop row direction is substantially poorer than that in the transverse loop row direction.

FIGURES 4, 5 and 6 schematically illustrate a fabric 8 of the present invention in which substantially improved definition pattern characteristics are evident in relation to the FIGURE 1 fabric.

The fabric 8 illustrated in FIGURE 4 is a tufted pile fabric having a parquet pattern identical to that involved in fabric 1 illustrated in FIGURE 1. As shown in FIG- URE 5, each transverse loop row 9 of fabric 8 includes a plurality of loops 1%) aligned at a first nominal height, i.e. a relatively low elevation, and another plurality of loops Ill aligned at a second nominal height, i.e. a relatively high elevation. As shown in FIGURE 5, the difference in elevation between adjacent high loops I1 and low loops It is substantially constant and the adjacent high and low loops are substantially all aligned at their desired nominal high and low elevations respectively.

As shown in FIGURE 6, each longitudinal loop row 12 includes a plurality of loops 13 aligned at a first nominal or low height corresponding to the elevations of the loops It of the transverse loop rows 9 and a second plurality of loops 14 aligned at a second nominal or higher height corresponding to the elevation of the loop rows 11. As shown in FIGURE 6, it is a characteristic of the present invention that adjacent high and low loops in longitudinal rows 12, such as the loops 14a and 13a are generally consistently aligned at their desired or nominal elevations such that the difference in height between adjacent high and low loops appears visually to be the same along the length of each longitudinal loop row. As a consequence of this relatively consistent accuracy of formation of loops in longitudinal loop rows and the accompanying relatively consistent accuracy of loop height formation in transverse loop rows, the fabric of the present invention is characterized by multi-directional consistency of pattern definition. The average difference in height between adjacent high and low loops 14 and 13 in longitudinal loop rows 12, in relation to the average difference in height between adjacent high and low loops 11 and 10 in transverse loop rows 9 is such that the height differences in both longitudinal and transverse loop rows in general appear visually to be substantially identical. In actuality, it will be understood that in the fabric 8 there will be some adjacent high and low loops 14 and 13, respectively, in longitudinal loop rows 12 which will have differences in height which will deviate from the average height differences in the longitudinal loop rows 12.

The high degree of consistency in average difference in height of adjacent high and low loops in both transverse and longitudinal loop rows provides a highly unique and vastly improved pattern definition in the FIGURE 4 fabric. Pattern definition characteristics, both longitudinally and transversely, appear visually to be the same so as to give the impression of 'multi-directional pattern uniformity. Whereas, in conventional fabrics such as the fabric 1 illustrated in FIGURE 1, pattern boundary lines such as the boundary 15 and the boundary 16 defined by adjacent high and low loops of contiguous longitudinal loop rows are generally jagged and uneven, the corresponding boundaries 17 and 18 of the FIGURE 8 fabric are relatively straight and accurately defined.

The improved pattern definition of the fabric of the present invention is illustrated in the FIGURE 7 photograph of a parquet patterned, tufted pile fabric 81 which corresponds to the schematically illustrated fabric 8 of FIGURE 4. Even a brief inspection of the photographic, plan view of fabric 8 will reveal the unique degree of accurate pattern definition in the longitudinal loop row direction and the high degree of consistency of pattern definition in both longitudinal and transverse loop row directions.

A representative transverse loop row 9 of fabric 8' is shown in an enlarged view in FIGURE 8. As heretofore noted, such a transverse loop row 9 is defined by the ends of contiguous or adjacent longitudinal loop rows defined by continuous strands. FIGURE 9 illustrates an enlarged, longitudinal loop row 12' comprising a continuous strand of the FIGURE 7 fabric. As shown in FIGURE 9, substantially all of the low loops 13 of longitudinal loop row 12 are aligned at the desired or nominal low loop elevation while substantially all of the high loops 14 are aligned at the desired or nominal high loop elevation. Thus, in each instance, the difference in height of adjacent low loops 13 and high loops I4 is generally consistent along the length of each loop row 12' and substantially corresponds to the average height difference of adjacent high and low loops If and It) in transverse loop rows The actual fabric illustrated in FIGURE 7 comprises a plain weave, ten ounce per square yard jute backing and pile loops formed from conventional, texturized, continuous filament nylon yarns of approximately 3700 denier and substantially lacking any twist. in each longitudinal loop row there are approximately 6 /2 stitches per inch. The gauge of this fabric, i.e. the center to center distance between longitudinal loop rows, is approximately of an inch. The loop height of the high loops 14 or 11' is approximately of an inch and the loop height of the low loops 13' or 10' is approximately of an inch. This fabric was finished by conventional dyeing and drying techniques. It is one example of a variety of fabrics which may be produced, for example, by the general method and apparatus disclosed in my copending patent application Serial No. 192,242, filed May 3, 1962, now Patent No. 3,089,442.

While the visual similarity in transverse and longitudinal pattern definition of the FIGURE 7 fabric is a striking structural feature, it is desirable to ascertain mathematically the approximate maximum degree of deviation of the average difference in height of adjacent high and low loops in longitudinal loop rows from the average difference in height of adjacent high and low loops in transverse loop rows. While this degree of 7 deviation is quite small in relation to that obtained in previously developed fabrics such as the fabric 1, it is significant to note that it reflects a degree of deviation which is permissible in a patterned fabric without detracting from optimum pattern definition properties.

To determine this degree of deviation a series of pile stitch length measurements were made in both longitudinal and transverse loop rows. In performing this analysis, the centers of the incremental portions of strands connecting the legs of adjacent loops were marked on the opposite sides of loops, the pile stitch lengths of which were to be measured. Thus as shown in FIGURE 12, if the pile stitch (S) of the loop 19 was to be measured, the center 20 of the incremental strand portion 21 on the back side of the fabric backing 22 would be marked as would the center 23 of the incremental portion 24. The strand 25 containing the loop I9, after the marking had been completed, was removed from the fabric and placed on a supporting table with the ends tensioned to such an extent that accurate linear measurements could be obtained. This tension was applied by hanging a 2.2 pound weight on each end of a yarn having pile stitch lengths to be measured.

In evaluating the deviation in question in connection with the FIGURE 7 fabric, it was determined that the average pile stitch length of yarn in the relatively high pile loops 14' lying adjacent low loops 13 in the longitudinal loop rows 12 was approximately 41.28/32nds of an inch. The average pile stitch length for low loops 13' in longitudinal loop rows 12' of the FIGURE 7 fabric was determined to be approximately 26.04/32nds of an inch. In each instance, the low loops 13 for which pile stitch length measurements were obtained were positioned adjacent to the high loops 14-. It was thus determined that the average difference in height between adjacent high and low loops I4 and 13', respectively, was approximately 15.24/32nds of an inch.

In measuring pile stitch length in transverse rows 9' in connection with adjacent high and low loops 11 and respectively, it was determined that the average pile stitch length for high loops 11' adjacent low loops 10' in transverse loop rows 9 of the FIGURE 7 fabric was approximately 41.89/32nds of an inch. The average pile stitch length of low pile loops 10' which were positioned adjacent to the high pile loops 11' in the transverse rows 9 was approximately 24.28/32nds of an inch. Thus the average difference in height between adjacent high and low loops 11 and lit, respectively, in transverse loop rows 1" was determined to be approximately 17.61/ 32nds of an inch.

From the foregoing data it will be observed that the average difference in length of pile stitches of adjacent high and low loops l4 and 13' of longitudinal loop rows 12' differs from the average difference in length of pile stitches of adjacent high and low loops 1]. and 10 of transverse loop rows 9 by approximately 2.37/32nds of an inch. This deviation, when expressed as a percent of the average pile stitch length difference in transverse loop rows, is approximately 13.5 percent. Here again, it may be observed by reference to the illustrations in FIGURES 7, 8 and 9 that there are at least some adjacent high and low loops 14 and 13' in the longitudinal loop rows 12 which have differences in height and thus in pile stitch length which obviously deviate from the average pile height and pile stitch length differences for longitudinal loop rows.

The aforedescribed multi-directional similarity of pattern definition produces a fabric characterized by unusual attractiveness and appeal. The blemishes associated with previously known tufted fabrics caused by undesired deviations in loop height from nominal or desired elevation inthe vicinity of pattern boundaries as defined by loops of different nominal elevations is substantially avoided or minimized. Over-all pattern definition is vastly improved and the directional orientation of maximum pattern definition associated with previously known fabrics is substantially avoided.

The fabrics of this invention, of which the FIGURE 7 fabric is an example, may be produced as described in my copending patent application Serial No. 192,242, filed May 3, 1962, now Patent No. 3,089,442, by impelling strands through tufting needles by directing flowing fluid against the strand peripheries. The gentle strand advancing force imposed by flowing fluid enables loops in a tufted fabric to be formed by strands which are drawn through a fabric backing and formed to their final configuration with a nominal applied force. Such tufted loops are substantially or relatively free of the deformation induced by stress applied longitudinally to strands according to previously practiced tufting techniques. In such previously employed techniques, strands are mechanically dragged through a backing by a needle and are usually sharply bent in the vicinity of the needle eye. The comparatively high tensile force imposed upon strands while forming loops by such conventional techniques tends to stress strands to such an extent as to tend to detract from the original degree of strand bouffantness and to cause the breakage of strand components such as filaments or fibers and to induce the separation of such components from the strand bodies. Such component breaking and separation is injurious to the crush resistance of a fabric and increases the likelihood of such components accumulation in unsightly rolls. The sharp bending of strands in the vicinities of needle eyes while the strands are drawn through the backing and extended to the height of the longest pile loops of a fabric tends to produce noticeable deformation of kinking in the vicinity of loop ends. This deformation detracts from loop fullness and thus detracts from the degree to which loops effectively cover or conceal a fabric backing.

It has also been observed, in producing the previously known fabrics, that loops terminating at different heights were subjected to different tensile forces. This has tended to produce an undesirable variation in fabric loop structural properties.

In minimizing or substantially eliminating strand deformation of the type heretofore described, the tufted loops of fabrics of the present invention substantially maintain their original body or bouffant condition so as to provide improved backing coverage properties. As will be appreciated, this is of particular consequence in that it enables a given amount of strand material to cover a greater area of fabric backing than could have been covered by strands tufted according to previously known techniques. The nominal force applied to strands to form loops according to this invention also contributes significantly to the obtaining of loop height uniformity as heretofore described. It further tends to minimize strand component breakage or separation so as to preserve the crush resistance of fabrics and minimize the accumulation or forming of rolls of separated strand components.

The nominal forces employed in forming tufted pile loops of the fabrics of the present invention are refiected in the following examples.

At a presently anticipated maximum rate of strand feeding contemplated for forming tufted piles in the fabrics of the present invention, it was ascertained, in connection with multifilament strands comprised of texturized continuous filament nylon of 3700 denier, that the maximum tensile force applied to the strands during any individual cycles of loop forming was approximately one ounce. In what is now considered to be a normal rate of strand feeding, the maximum tensile force applied to such nylon strands during any cycle of loop forming was determined to be approximately 20 grams. In this same normal operating range where pile loops were formed in a fabric from 2-ply wool strands having a yarn size of 2.57 based on the cotton system, the maximum tensile force exerted on the strands during any cycle of loop forming was determined to be slightly less than 18 grams. It thus may be concluded that with strands commonly employed in forming tufted pile fabrics such as continuous filament nylon and wool strands, the maximum tensile force applied to a strand while it is drawn through a fabric backing and formed into loop configuration does not exceed approximately 20 grams at the normal rate of strand tufting.

An additionally significant observation may be made with respect to the tension exerted upon a strand while it is being formed into pile loops of different heights in the fabrics of the present invention. It has been observed that in a tufted pile fabric, such as the FIGURE 7 fabric which has a pattern defined by pile loops having relatively different heights, and which includes longitudinal loop rows defined by continuous strands having at least one plurality of loops generally aligned at a first nominal height and another plurality of loops aligned at a second nominal height, that the loops aligned at both heights were formed, by strand portions which were drawn through the. fabric backing and formed to their final configuration with substantially the same maximum tension force applied to the strands.

In tufting certain fabrics of the invention, such as fabrics having pile loops formed from strands which prior to tuftingxeither substantially lacked strand twist or had a relatively low twist, and had either low or no residual torsional strain, there may result a unique orientation of loop leg portions which contributes to an enhanced fabric appearance.

Fabrics produced by previously known conventional tufting techniques produce a generally consistent loop orientation as indicated in FIGURES 10 and 11. As there shown, a strand 26 has loop portions 27 which project through a fabric backing '28. As illustrated in FIGURES lil-and 11, leg portions 29 and 30 of each loop 27, in the areas where the strand 26 passes through the backing 28, are arranged in a generally overlapping or side by side orientation. As a result of this non-coplanar orientation of the leg portions 29 and 30 along the length of the strand 26, the upper portion of each loop 27 tends to be turned or twisted in relation to the general plane of the strand 26 such that the central axes of the curved portions of the loops 27 lie in planes which are transverse to the general direction of tufting of the strand26. This often results in an alignment of loops in each strand 26 which visually emphasizes or distinguishes the loop row and thus produces a pronounced row effect.

FIGURES l2 and 13 reflect, in comparison to the pre viously known loop structure shown in FIGURES l and 11, the unique loop leg orientation which may be achieved in the present invention. Through observation it has been found that a majority, or in many cases, substantially all of the loops in any longitudinal or continuous strand 25 of a fabric of the present invention may be oriented as illustrated in FIGURES 12 and 13. It will be understood, however, that it has also been observed that in all instancesthere exist at least some loop legs in almost all loop rows which are not oriented in the manner shown in FIGURES 12 and 13, but which are oriented more or less in the manner illustrated in FIGURES l0 and 11.

The loop orientation illustrated in FIGURES l2 and 13 involves a substantially coplanar alignment in any loop row of the incremental strand portions 21, which lie on the back face of a backing and connect adjacent loops, with the leg portions of the loops in such a row such as the illustrated leg portions 31 and 32 of the loop 19 in the area where the loop 19 projects through the backing 22. This unique loop portion orientation is more clearly reflected in the cross-sectional view of FIGURE 13. As there shown, the central axes of the incremental strand portions 21 and 24 and the central axes of the leg portions 31 and 32 are generally aligned such that they are substantially coplanar or at least appear visually to be generally coplanar in nature.

The result of the unique loop leg orientation illustrated in FIGURE 13 is to tend to make the over-all central axes of the loops in any strand such as strand 25 substantially more coplanar or approach a coplanar condition to .a much greater degree than do the loop axes of the conventional fabric structure represented in FIGURES l0 and 11. This unique orientation of loops, even though it may involve a majority and not all of the loops of the fabric, tends to substantially offset visible rows of loops aligned longitudinally in the fabric, i.e. in the direction of tufting. It is believed, from observations to date, that the degree of this unique orientation achieved in a fabric may tend to increase as the degree of torsional strain decreases. Torsional strain, as here used, refers to the degree of torsional strain which exists in strands prior to tufting.

The aforedescribed elimination of longitudinal row emphasis is illustrated in the photograph of a patterned fabric made according to the present invention, shown in FIGURE 14. This fabric, which has a conventional jute backing, was produced with conventional texturized continuous filament nylon strands of approximately 3700 denier having a twist of about one-half turn per inch and substantially lacking any torsional strain. The relatively high pattern areas in the fabric illustrated in FIGURE 14 have a loop height above the fabric backing of approximately of an inch. The low pattern areas are defined by low loops having a loop height of approximately of an inch. The distance between loops in longitudinal rows is such that there are approximately six loop stitches per inch in each such row. The gauge of the fabric is approximately of an inch between centers of adjacent longitudinal rows. By examining the plan view photograph of the fabric shown in FIGURE 14, it will be observed that in the longitudinal loop row direction, i.e. the direction of tufting, the fabric is characterized by a substantial absence of visibly defined loop rows.

While the structural properties of the improved fabric of the present invention, as previously described, are significant in enhancing the appearance and general desirability of normal fabrics, they also enable the production of unique fabric patterns which have heretofore been found impractical or altogether impossible to produce. In FIGURES 15, 16 and 17 there is schematically represented a tufted fabric having such unique patterned portions.

In the plan view of the tufted pile fabric illustrated in FIGURE 15, there is shown a pattern including visible grooves 33 running transversely, i.e. normal to the direction of the tufting. There is also illustrated a shallow depressed pattern area 34.

The depressed pattern area 34 is unique in that the elevation of loops 35 within the interior of the area 34 differs from the elevation of loops 36 surrounding the area 34 by no more than A of an inch. Despite this nominal difference in loop height, the shallow pattern area 34 is well defined even in the direction of tufting, i.e. along the length of continuous strands defining loops 35 and 36. With the erratic and inconsistent loop definition generally encountered in previously known tufted pile fabrics, it would have been altogether or nearly impossible to produce such a shallow pattern which would be accurately and consistently defined and visually discernible so as to be acceptable to normal consumers.

The narrow grooved portions of the FIGURE 15 fabric such as the transverse grooves 33 are particularly unique in that they comprise pattern portions having a width which may be as narrow as the width of a single tufted loop. As shown, for example, in FIGURE 17, which comprises a cross-section of the groove 33, the groove 33 is defined by relatively high loops 37 and 33 in continuous strands 39, which loops lie on opposite sides of a relatively low, single loop 40. Because of the vastly improved consistency and accuracy in loop height formation which characterizes the fabric of the present invention, the narrow pattern area such as the groove 33 having a width corresponding to the width of a single loop, is so well defined as to be readily discernible to the naked eye.

It will be appreciated, of course, that in fabrics of the present invention, such shallow and/or narrow pattern formations as those described may comprise elevated areas as well as depressed areas and may comprise zones having loops of one height on one side and loops of still another height on the opposite side.

In describing fabrics of this invention, examples have been employed comprising patterns defined entirely by loop pile-s. However, it will be appreciated that the invention embraces as well, tufted pile fabrics having pile loops at least some of which may be sheared, cut, napped, or otherwise altered.

In describing the over-all invention, and the various individual structural features which may be attributed to the fabric of the invention, the advantages of these features have been made readily apparent. In summary, they comprise a vastly improved degree of pattern definition,

7 degree of uniformity in height of loops desired to be aligned at any particular nominal height, and loops which were formed to their final configuration with nominal or relatively low tension forces. The fabric is further characterized by a a degree of pattern definition in the direction of tufting which corresponds to the degree of pattern definition transversely of the direction of tufting. The fabric may be additionally characterized by an improvement in the extent to which tufted pile loops cover a fabric backing, by improved crush resistance of the pile fabrics, by an enhanced resistance to a tendency for individual strand components to accumulate in rolls as a fabric undergoes normal Wear, and by a reduction in the number of weakened or broken or withdrawn strand components. In certain instances the fabric may additionally be characterized by a unique orientation of loop leg portions which may tend to minimize or obviate a visible alignment of loops in the direction of tufting. Certain fabrics of the invention may also be characterized by unique, visibly discernible, .and' accurately defined pattern portions characterized by extreme shallowness or narrownes-s.

The invention has been described with reference to several specific embodiments which have been illustrated and described in detail. However, various modifications and variations from the specifically illustrated and described fabric structures may suggest themselves to persons skilled in the art. It is intended, therefore, that the foregoing description be considered as exemplary only, and that the scope of the invention be ascertained from the following claims.

What is claimed is:

1. A tufted fabric comprising a backing and a plurality of rows of tufted loops of yarn. each said loop row comprising a continuous strand including loop defining portions projecting from one side of said backing, said loop defining portions having leg portions which extend through said backing to the opposite side thereof, with adjacent leg portions of adjacent loops in each row being connected on said opposite side of said backing by incremental strand portions, said fabric being characterized by a majority of said leg portions and said incremental portions of each loop row being aligned such that their central axes are substantially coplanar, and in which the loops are further characterized by a fiufiiness characteristic of air blowing and having outer portions of the yarn of adjacent loops intermingled so that adjacent loops provide both lateral and longitudinal support for each other and so that the visible alignment of loops in the direction of tufting is substantially eliminated.

2. A tufted pile fabric including a backing and having a pattern defined by tufted pile loops of yarn, said loops having relatively different heights, said fabric including longitudinal loop rows defined by continuous strands and having at least one plurality of loops generally aligned at a first nominal height and another plurality of loops generally aligned at a second nominal height, said loops being characterized by a random fluffiness characteristic of air blowing and having outer portions of the yarn of adjacent loops interengaged and substantially filling the spaces between adjacent loops so that adjacent loops provide both lateral and longitudinal support for each other and the visible alignment of loops in the direction of tufting is substantially eliminated.

3. A tufted pile fabric including a backing and having a pattern defined by tufted pile loops of yarn, said loops having relatively different heights, said fabric including longitudinal loop rows defined by continuous strands and havin at least one plurality of loops generally aligned at a first nominal height and another plurality of loops generally aligned at a second nominal height, said loops being characterized by a random fluifiness characteristic of air blowing and having outer portions of the yarn of adjacent loops interengaged and substantially filling the spaces between adjacent loops to form a substantially continuous mass so that adjacent loops provide both lateral and longitudinal support for each other and the visible alignment of loops in the direction of tufting is substantially eliminated.

4. A tufted pile fabric as defined in claim 2 and in which the loops in longitudinal loop rows are also aligned in transverse loop rows and wherein the average difference in height between adjacent loops at said first and second nominal height in said longitudinal rows is visibly substantially identical to the average difference in height between adjacent loops at said first and second nominal height in said transverse rows.

References ited by the Examiner UNITED STATES PATENTS 2,750,652 6/1956 Pctroske 161-66 2,766,506 10/1956 Rice. 2,782,905 2/ 1957 Smith 11279.6 2,966,866 1/1961 Card 1l279.6 3,067,701 12/1962 \Vilcox 112-79 3,089,442 5/1963 Short 1'1279 JORDAN FRANKLIN, Primary Examiner.

I. R. BQLER, Assistant Examiner. 

1. A TUFTED FABIC COMPRISING A BACKING A PLURALITY OF ROWS FO TUFTED LOOPS OF YARN, EACH SAID LOOP ROW COMPRISING A CONTINUOUS STRAND INCLUDING LOOP DEFINING PORTIONS PROJECTING FROM ONE SIDE OF SAID BACKING, SAID LOOP DEFINING PORTIONS HAVING LEG PORTIONS WHICH EXTEND THROUGH SAID BACKING TO THE OPPOSITE SIDE THEREOF, WITH ADJACENT LEG PORTIONS OF ADJACENT LOOPS IN EACH ROW BEING CONNECTED ON SAID OPPOSITE SIDE OF SAID BACKING BY INCREMENTAL STRAND PORTIONS, SAID FABRIC BEING CHARACTERIZED BY A MAJORITY OF SAID LEG PORTIONS AND SAID INCREMENTED PORTIONS OF EACH LOOP ROW BEING ALIGNED SUCH THAT THEIR CENTRAL AXES ARE SUBSTANTIALLY COPLANAR, AND IN WHICH THE LOOPS ARE FURTHER CHARACTERIZED BY A FLUFFINESS CHARACTERISTIC OF AIR BLOWING AND HAVING OUTER PORTIONS OF THE YARN OF ADJACENT LOOPS INTERMINGLED SO THAT ADJACENT LOOPS PROVIDE BOTH LATERAL AND LONGITUDINAL SUPPORT FOR EACH OTHER AND SO THAT THE VISIBLE ALIGNMENT OF LOOPS IN THE DIRECTION OF TUFTING IS SUBSTANTIALLY ELIMINATED. 